9-22 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

•Install new bolts and nuts in reused connecting rod.

If the connecting rod assy was replaced, use the bolts and nuts attached to the new connecting rod assy.

•Apply a small amount of molybdenum disulfide oil solution to the following portions.

Threads [A] of Nuts and Bolts

Seating Surfaces [B] of Nuts and Connecting Rods

•First, tighten the nuts with 11.8 N·m (1.2 kgf·m, 104 in·lb) of torque.

•Next, tighten the nuts 180° .

○Mark [A] the connecting rod big end caps and nuts so that nuts can be turned 180° [B] properly.

Crankshaft/Connecting Rod Cleaning

•After removing the connecting rods from the crankshaft, clean them with a high-flash point solvent.

•Blow the crankshaft oil passages with compressed air to remove any foreign particles or residue that may have accumulated in the passages.

Connecting Rod Bend Inspection

•Remove the connecting rod big end bearing inserts, and reinstall the connecting rod big end cap.

•Select an arbor [A] of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end.

•Select an arbor of the same diameter as the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor [B] through the connecting rod small end.

•On a surface plate, set the big-end arbor on V block [C].

•With the connecting rod held vertically, use a height gauge to measure the difference in the height of the arbor above the surface plate over a 100 mm (3.94 in.) length to determine the amount of connecting rod bend. If the connecting rod bend exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Bend

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

CRANKSHAFT/TRANSMISSION 9-23

Crankshaft and Connecting Rods

Connecting Rod Twist Inspection

•With the big-end arbor [A] still on V block [C], hold the connecting rod horizontally and measure the amount that the arbor [B] varies from being paralleled with the surface plate over a 100 mm (3.94 in.) length of the arbor to determine the amount of connecting rod twist.

If the connecting rod twist exceeds the service limit, the connecting rod must be replaced.

Connecting Rod Twist

Service Limit: TIR 0.2/100 mm (0.008/3.94 in.)

Connecting Rod Big End Side Clearance Inspection

•Measure connecting rod big end side clearance. ○Insert a thickness gauge [A] between the big end and ei-

ther crank web to determine clearance.

Connecting Rod Big End Side Clearance

If the clearance exceeds the service limit, replace the connecting rod with new one and then check clearance again. If the clearance is too large after connecting rod replacement, the crankshaft also must be replaced.

Connecting Rod Big End Bearing Insert/Crankpin Wear Inspection

•Remove the connecting rod big end (see Connecting Rod Removal).

•Cut strips of plastigage to crankpin width. Place a strip on the crankpin parallel to the crankshaft installed in the correct position.

•Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation).

NOTE

○Do not move the connecting rod and crankshaft during clearance measurement.

•Remove the connecting rod big end again, measure each clearance between the bearing insert and crankpin [A] using plastigage (press gauge) [B].

CAUTION

After measurement, replace the connecting rod bolts and nuts.

Connecting Rod Big End Bearing Insert/Crankpin

9-24 CRANKSHAFT/TRANSMISSION

Crankshaft and Connecting Rods

If the clearance is within the standard, no bearing replacement is required.

If the clearance is between 0.082 mm (0.0032 in.) and the service limit (0.11 mm, 0.0043 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/crankpin clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure. If the clearance exceeds the service limit, measure the diameter of the crankpins.

Crankpin Diameter

Standard: 29.987 30.000 mm (1.1806 1.1811 in.)

Service Limit: 29.98 mm (1.1803 in.)

If any crankpin has worn past the service limit, replace the crankshaft with a new one.

If the measured crankpin diameters are not less than the service limit, but do not coincide with the original diameter markings on the crankshaft, make new marks on it.

Crankpin Diameter Marks

None 29.984 29.992 mm (1.1805 1.1808 in.)

○29.993 30.000 mm (1.1808 1.1811 in.)

: Crankpin Diameter Marks, “○” or no mark.

•Measure the connecting rod big end inside diameter, and mark each connecting rod big end in accordance with the inside diameter.

•Tighten the connecting rod big end nuts to the specified torque (see Connecting Rod Installation).

NOTE

○The mark already on the big end should almost coincide with the measurement.

Connecting Rod Big End Inside Diameter Marks None 33.000 33.008 mm (1.2992 1.2995 in.)

○33.009 33.016 mm (1.2996 1.2998 in.)

Big End Cap [A] Connecting Rod [B] Weight Mark, Alphabet [C]

Diameter Mark (Around Weight Mark) [D]: “○” or no mark

CRANKSHAFT/TRANSMISSION 9-25

Crankshaft and Connecting Rods

•Select the proper bearing insert [A] in accordance with the combination of the connecting rod and crankshaft coding.

Size Color [B]

•Install the new inserts in the connecting rod and check insert/crankpin clearance with the plastigage.

Crankshaft Side Clearance Inspection

•Insert a thickness gauge [A] between the thrust washer [B] on the crankcase and the crank web [C] at the #3 main journal to determine clearance.

If the clearance exceeds the service limit, replace the thrust washers as a set and check the width of the crankshaft #3 main journal.

Crankshaft Side Clearance

Standard: 0.05 0.25 mm (0.0020 0.0098 in.)

Service Limit: 0.45 mm (0.0177 in.)

•Measure the width [A] of the crankshaft #3 main journal [B].

If the measurement exceeds the standard, replace the crankshaft.

Crankshaft #3 Main Journal Width

Standard: 21.09 21.14 mm (0.8303 0.8323 in.)

Crankshaft Runout Inspection

•Measure the crankshaft runout.

If the measurement exceeds the service limit, replace the crankshaft.

Crankshaft Runout